1. Fabric flaws: mostly narrow width, missing code, pinholes, loose / broken yarn or a yarn slip, thin or thick material, poor images due to blurred printing, misprints, such as double printing, slops, uneven stripes in the printing, dark colored printing, light color printing, printing that diminishes in size, smudges / stains, lapels, joints, missing hair or damage on Jing-cloth, layers coming apart from Jin-velvet cloth, yarn stretching on nylon fabric, wrinkled fabric made of cloths and other things similar in nature, cheap quality cloth, water leaking out, moths being present.
2. Other fabric flaws: revealing too much plush hair, hair loss, yarn slips, rotten holes, nip holes, rough surfaces, low elasticity, poor quality cloth, sand colored cloth, with light surfaces, dull hair and poor quality.
3. Other details: scratches on artificial leather, nip holes on artificial leather, poor quality seams, layered fabric at the bottom, punching holes into a material, nicking leather of very mild color, molds on light colored sand paper.
4. Inaccurate dimensions: wrong length, width and height, harder shelf and softer color difference, wrongly glued/nailed interfaces, wrongly marked boxes, dull and blurry boxes, double printing of boxes, some letters or pictures being missing from the prints, unknown variety of corrugated boxes.
5. Errors: wrong regulation size which is not matching the thickness of the punching holes, slightly blurry artificial plastic print, wrong prints on the artificial plastics, plastic fabrics being torn and dirty, covered in oil stains with told how did this happen, poorly constructed bags.
6. Further details: Instructions containing not enough sheets or pages, hazy, damaged, and faint ink prints or ink not present in places, missing pictures, wrong pattern on the print, mismatch of colors in the printed patterns.
7. Physical verification approach: Place the cut pieces in a single layer, allow the cut pieces to relax to the maximum, juxtapose the signed card with the cut pieces as endorsed by the engineering department completely to find variations, then check whether the wool direction is reversed, then if the wrong type of material has been employed (usually one knife from the left side, one from the center and one from the right is taken), as the general rule of thumb, wool pieces are purchaseable if cut pieces acceptance reason range differs by 0.5 cents approximatelly speaking and for cloth cut pieces the tolerance is 1/32 inch or so, depending on the particular circumstance the final decision is made, hypotenuse of the same bag pieces medium differentials will not harbor yin and yang color tones, ho, harbours of the same fabric coordinate pieces will not have do, hematocyst harbours or stations with different miscellaneous wool hemispheres, do not contain various design points around the stalks, the colour most of the time is ok and not decayed, too much applying of pressure on them while cutting is what's not acceptable.
8. Test of Cutting crushing die: Horizontally, put the acceptable slotted paper pattern within the relevant slotted cutting die. If some edge touches the cutting edge all of its parts from all angles contact too. A loose or displaceable situation indicates that the cutting die requires modification and would be set on a plate of class after gamma-ray sterilization and proper placement. Cut the piece in two hours and rest the die every 8 hours for up to an average of three times per day or any required number of times and examine it for distortion, breakage and obstruction of the waste hole among other problems.
9. Fabric inspection method: Losing fabric to be inspected on a certain fabric is done freely and then tensioning the cloth seal and measuring its length is done after the material is hanging freely. Making cuts of 6X6 inches on fabrics from the back, front, and center, and then after that relative direction of the fibers, coloring, and pattern of the fabrics are all observed. After this, the amount of the incoming material is calculated by using the reference weight (36 times of the measured weight), and the weight in actuality turns out to be ‘1Y as that fabric which weighs 36X is considered to be that actual amount of that material’, and when appropriate fabric elongation test is carried out. Single piece of fabric is grabbed and sewed, then afterwards sewing site is adjusted to the required amount and shape based on horizontal and vertical creeps and twills (by cutting if needed). As appropriate further parameters can be satisfied, hair length, material, weight, tearing of a fabric and even changing its color (both wet and dry grinding) tests can be conducted. It is mandatory to undergo dry and wet grinding tests on the coated part of fabric screen. Japanese hygiene tests are also necessary for the clients working with SMI.
10. Elements: When it comes to noses and eyes, accessories such as them need to be tried with particular substances in terms of strength, lifespan, and environmental impact. Eyes and noses, like other accessories, have to be painted according to their size, and segments need to be proportioned to the rest of the head closely. Sprayed parts and pad printing parts must undergo an alkaline oil boundary and rubbing and aging tests. Saltwater has to be tested on hardware alongside clean water. In addition, a crossbow decolorization test has to be done to standardize incoming materials for trademark requirements. 40/3 thread is 3 strands thin and over 3 pounds and 60/4 is two strands thicker than 40/3 thread. It is more durable than 40/3 thread in terms of tensile testing, needing over 5 pounds to break. Thicker than 60/4 thread are 60/6, 3 strands of thread, and 20/9, 9 strands of thread, while 60/8 is 4 strands of thread. Wax thread has the ordinary ones thread which is easier to use and less brittle after being waxed but 60/4 requires more than seven pounds.
11. Carton: Utilize good quality control practices by looking at the printed content of the box, the effective graphics designs and copy of the carton, then seal it in a box and record its length, breadth, and height. Noting (during the measuring) whether the measure is flat (whether all angles are perfect right angles or large cut seam joint at the joining edges). In addition, the carton need to subjected to static pressure test and box drop test ( test the quality of the carton).
12. Cut pieces and its possible problems and solutions: There is a problem with the cutting table during the production process whereby the cut pieces are too small.
a. The causes are: The cloth loosening time is inadequate; there are an excessive number of cloth layers yanked and the die is too small, where the elasticity of the fabric is excessive, making the cut pieces to be large, the die deformation to be large, the cloth to be too slack and wrinkled while too much elasticity of the fabric was employed.
b. Recommendation: Fix the die, decrease the number of pulling when cutting the cloth or place a layer of paper in between the layers of cloth in order to reduce the elasticity of cloth in cutting. The cutting net be prepared in a completely stretched form and the loosening period is adequate. In cases where excess elasticity cutting is cutting, or processing the cloth in this case should be done separately, causing the number of cutting more to be minimum number of layers. The provided die must be placed firmly before cutting commences.
13. Reasons for the deformation of the cut pieces and the missing points are: the die cuts on the resin and this does not take into consideration the fact that the fabric itself has some elasticity, so it cannot cut the die smoothly taking into account the dies location. The die getting left too little space from the mouth, sudden movement of the crumpled or folded cloth material across the mouth cut's head and tail portions introduction, incomplete manual cut segments of the head and tail portions also can induce all deformation cuts of the cut pieces not shear part.
14. Improvement method: The die has to be maintained in which case the die is disfigured. As a rule, in order to save materials, some die can be cut in halves. Therefore, there is a requirement to half the knives used in constructing these dies. Generally, all the mouths of the dies are half cut. However, attention should also be paid in cutting the mouth as well in order to preserve materials. However, some dies can be used to change the knife and pull the cloth, and the eleven position cut pieces are selected and useless. The uncut cut pieces can only be cut with a scissors and cannot be pulled off.
15. The phenomenon of sponge yellowing: that some sponges will foster oxidation and hence get yellow when left in the air or sunlight or lamp for a long time.
Solution. Isolation from any direct sunlight, do not expose into sunlight or apply yellowing agent (that is, the cut pieces can be wrapped with black plastic bags).
16. The reasons for the confusion of the cut pieces: wrong positioning of die, incorrect cloth pulling (single palm or closing) and the workers that collect the cut pieces do not position the upper and lower hairs accurately.
Solution: Follow the engineering data requirements exactly as stated and emphasize during the guidance meeting regarding the direction of upper and lower wool then gently wrap bottom and upper portions separate.
17. The significance of disjointed cut pieces is represented by the two colors. There are two colours that IQC does not separate when it takes the parcel and there are two colours because the piece of the cloth is designated the wrong shade or a’s wrong colour is pulled by the cloth puller.
Solution: Standard data on color separation is maintained by the IQC, which is also well defined, and sends it to the cutting table department in writing direction. It will do so by informing the cutting table about the colors to be in that particular piece and their corresponding numbers. If the cloth being operated has two colors, the cloth can be cut at the interface where the color borders cut it in a more confounding color, the entire piece cloth is sent back to the supplier and do not proceed with production. The cloth being pulled by cloth puller instead uses I.Q.C. color separation data.
18. The die is placed tilted, cloth is pulled tilted, cloth pattern itself is tilted or the piece of cloth is torn.
Solution: Make sure that all these parameters are checked when pulling the cloth. If there is any defect, that unrequisite piece of cloth is returned to be supplier.
19. Seams of fabric: Up to 30 layers of T/C cloth are applied, sheared cloth can apply up to 12 layers, for fabric that is too elastic, a layer can be modified to 8 to 10, with white paper however, plush fabric is commonly 6 to 8 layers, leather and fabric with a single design are usually 6 layers, and all fabric stretching time is 12 to 24 hours.
20. A hot die of cut and mold inspection: the hot die of cut and mold consists of flat heating wire and high temperature resistant board about it. First, with the engineering werq card effective paper , go to over the designated area on the hot cut mold. If they are exactly overlapped it passes, and if the tolerance is 1mm or less it passes. Then determine whether the hot cut wire is short and power connecting strip is not exposed and the screw pin fully screws.
21. Issues and remedies associated with hot cutting pieces: With regard to hot cutting fabrics are usually seen to have a long plush fabric (more than 10mm in thickness) but in some other instances 6mm plush is sometimes hot cut (depending on the needs). It burns the bottom yarn of the plush cloth in order to cut the pieces meaning cut off the printing.
a. Factors contributing to the small sizes of the cut pieces cutting include: excessive heating of the bottom yarn (top edges) as a result of heating the wrought iron too long, the cut knife is small, or the peg wolfshead is pulled too much.
b. Recommendation: change the voltage to a reasonable range. Plus, the optimum temperature cutting knife is needed. In case of too high, the more heated wire gets. The cutting knife should be on the move because it has a complexing centre. Cutting knife die should be checked thrice on a 1-day basis Cutting cloth (single layers) apply moderate pulling force given the fact that too much force will greatly compact the bottom yarn.
22. The burnt or rotten cut pieces can be said to be caused mainly by high temperature of the knife die, small cutting mouth, or unskilled and inaccurate operational gestures of the workers. Steps for Improvement: reduce the temperature (the voltage is turned to the required numbers and the track type hot cutting method is used which precise and fast hence minimizing cut pieces wastage).
23. Hot Cutting wire breakage tolerance is quite low: It is enough to use a spot welder to connect a small section of broken arm wire to a broken piece. It is more appropriate to lay a short piece of heating wire on the outer side of the mold wire to make sure that the cut pieces are acceptable.
24 - The problems resulting in even a toeing of sewn products: Also- seam edges skewed, seam points are incorrect, throat of the needle is of the wrong size, bones of the rifle collar are not in line, folds have wrong stirrup measurements, pesky over stitching of cut pieces, inaccurate stitch wrinkles practically everywhere, duck coloration is abnormal, amount of stitching , stitch mounting rotation, knitted tapes aren’t finished off, reverse stitch missing and pin holes appear, underneath the seam loose threads, different or wrong sewing materials are used, pieces of fabric have not been sewn, gathered and heal area is burst, faulty fabric, touches were not sewn, improper hair cutting techniques were applied, seams splitting, parts that should have been stitched aren’t there, seams are knocked to one under the bottom half of the two pieces, the seam is not taunt at places and because of this an inch of nail can poke it, fabric is cut but the pieces sewn together left some two pieces unsown thus making it lumpy, surprise surprise oh look the fabric was soaked in water whilst the glue required degreasing, the melt column has not been high enough making the cigars weak and burning only partially in hot ash and fire, excessive heat in the burning and the fabrics sticks with the cigars itself along with the eye area of the dew drops, and the sad part is that all the direction cables or the parts for the sewing head cover got burnt off.
a. Sewing inspection method: general checking, occasional checking of the sewing process and occasional checking after the project is done, integrating the three factors of the sewing product inspection methods, we first examine the wool color to see if it corresponds, following the check of the opening size of the seam, the edge alignment, point alignment, the prescribed stitch size, stitches omissions, sewing machine operation, wrinkling, proper seam bottom line tension, vertical and horizontal bias to the fabric, sewing MOVEMENT, follows with examining the upper lip to see if the threads are intact and in conclusion we check for symmetry of the different body features which include the eyes, nose and complete other body parts such as ears, even checking if there are adornments such as coils in the leather covering that will reach final screening by the metal scanner.
b. Remedies for Cut pieces with regards to sewing problems: If pieces are cut in the form of cups and points are reduced off, the two associated cup cut pieces can be clamped on the two fixed points and then cut and or color removing pens can be used to fix the points marked
25. Cut pieces loose: If there are some loose parts, you can cut off the edge as one more line die is first pressed into place. A hot pressed custom die can also be used but at a lower temperature. Also, hot fusion glue can be used to seal the edges, and in case of need, one can also wrap and lock the edges.
26. Cut pieces are too small: Reduce sewing gaps to a level which can be required without changing tension.
27. Cut pieces are too large: In case if the cut pieces are not having any noticeable size and are similar, you can use push and pull while sewing. Alternatively, the procedure is to sew the cut pieces before increasing in size and afterwards join the related pieces. If this alters the cut pieces’ appearance, it is advisable that surplus portions be trimmed from the cut pieces’ borders, or the cut pieces moved without having the edges matching with the seam.
28. Specific sewing technique to adjust the size of the cut pieces: Reduction of the upper thread and inclination of the lower thread (or vice versa as required).
29. In situations where there are beads in the sewing position: the line can be tightened (the upper and lower threads are moderately tensioned). If it is thinnest fabric or quite slippery, the fabric can be put on top of a layer of paper while sewing. There is insufficient tension at the bearing force portion.
a. Add double sewing bottom line, sew with one line of thread as sewing thread, reverse needle, stick cotton tape of poor material quality, change the position of sewing or change the stress point to the arc position but without changing the appearance.
b. You may also do the needlework by curling the edge first and then sewing it. In the case sometimes, thick needles or dense stitches are used, the fabric is occasionally torn from the cotton tape by using the needles at incorrect heights or sinking it in at the wrong depth, this happens due to poor quality of materials and wrong sewing style or sparse stitches, broken threads, missing stitches or damage to materials due to insufficient tension. Also fabric grains can be rotated without affecting the appearance.
30. The employment of Ruth’s belt-cord has some tension, one purpose of the belt- cord is that one end portion of belt or cord may be stitched to the cut portion by turning it over. Likewise, belts and cords can be sewn after being tied together at one end but the hot cut end will be free. And if required, reverse sewing should be done. Reverse sewing is usually at least two or three stitches although it may be more which in the normal case is more than an edge. In the event that different colored cut pieces are cut, it is a requirement that different colored cut pieces should be sewn with a like colored thread.
a. When the sewing is carried out at the less visible part of the item or the cut piece area is very small, it follows that the color/hair direction may be unimportant. It is true that for the head, face and other supposed parts of plush doll, color and hair direction must be stitched. For other spent cut out bodies pieces, it is better that can be produced with respect to the fact part of the durability of the embroidery.
b. In some cases, positioning sewing can be applied for certain doll body accessories. Fading pen points may be used to indicate guides, or construction may occur on a sewing platform. With a sewn product, it needs to be convenient to turn the skin around.
c. In some cases where turning the leather becomes tedious, several other methods can be used to turn the leather (for instance: inserting a belt and then sewing it, or forcefully pulling the edge of the belt to get it turned, etc.) or get it sewn and turned afterwards for particular bleached textiles.
e. As to minimize the wear of the printed image under stress while making a turn of leather: one may employ tape in a single sided covering of the image or inject tiny portions of cotton to ease the friction before turning the leather, or alter the location and dimensions of the window cut.
31. How to deal with problem with also drilling holes: With single drillings, by making allowances and deviations in the hole’s diameter that are within the range of 1-2 mm, this would permit the lodgement of the required drill’s diameter into the needed symmetrical position within the hole which could cause it to be symmetric.
a. Possible causes are: wrong positioning of the eyelet, missing the eyelets altogether, the thickness of the fabric being too thin and the eyelet column having reached the maximum, or the flat positioning of the eye holes that contains inclusions, or generation of the mold height and size for the said cavity and sometimes weakness in the strength of the puncher’s casing.
b. Solution: Correct the position of the eye meson if it is wrong. If it’s incorrect, send it back for replacing. Where the material is okay, the problem may be with the mold’s accuracy, so check it. If yes, fix the mold. If the first two are alright, put an extra eye (but the cost has increased). Verify if the operator has leveled the eye meson, the amount of force should be appropriate. A foot can also be added onto the meson. To bind meson for adding a bone location to aid rotating skeleton although this might slow down the pace.
32. Eye nail bursts occur due to several factors like problems with the quality of the eye, excessive force, unaligned molds, uneven height of the mold, and low level of the eye. Simply put there exists a gap between mushrooms or the rubber itself.
Solution: Try to solve the problem by eliminating the root cause in case of sight related issues seek to return or replace the eye which may solve the problem. Similarly Operate differently in case of operational issues providing the lower or upper molds with a corrective height may also suffice.
34. It is required that molten columns remain after cutting where burning eye columns take a mushroom shape. The cutting tool when being too low is likely to break resulting in the eyes falling off while cutting the tool being too high may loosen the eyes during the tensile test both of which go against the protocols provided by the toy industry.
35. Such issues may arise as decayed material, flipped hair loss and inability to fit during moments of leather flipping.
36. Solve this problem: As a rule, the bigger component is externally rotated first before the other components are. The leather column tip of the flipping iron is provided with a cloth cover so that the fabric is not rotted during leather flipping. Make sure to observe the sequence and techniques used in leather flipping. As for some tiny parts, you can also place a small amount of cotton in it before leather flipping. This minimizes the fiber puckering which tends to rub the flipped column’s material surface and it becomes easy to flip. The edge of the leather gun should not be overly pointed and high thumb gripping force should not be applied.
37. After bed type machine has been provided with normal adjustments, pressing of the product must take place in from one side to another in the provided limits. Each part of the machine has to be flat against the surface of the machine and, the other side is turned over and pushed or moved to see if it has a bed.
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